Wire box assembly

ABSTRACT

A wire box assembly is disclosed that has a container having a base, four upright side walls and a separable lid. The base has a generally rectangular peripheral shape and a central raised portion with a cruciform projection extending inwardly upward between the upright side walls. The lid has a generally rectangular peripheral shape configured to mate with the four upright side walls of the container and having a central raised portion with a cruciform projection extending from the central raised portion. The lid cruciform projection is configured to face the container cruciform projection when the lid is attached to the container.

BACKGROUND

In the world of residential and commercial building construction, there are many different types of wire types used. Some extremely common wire types are Cat5 and Cat6 (data and voice wire), 16/2 (speaker wire), 16/4 (speaker wire), 22/2 and 22/4 (commonly security wire) and 18/2 2pair shielded (commonly line level wire). These are a few examples of wire types that are sold in very high volumes throughout the world that can be purchased pre-wound in a coil and packaged in cardboard boxes. The cardboard box that houses the wire is taped shut on the seams. When an installation worker pulls the wire end out of the box, the wire can become twisted and knotted. If a knot occurs in the box the tape must be cut and the box must be opened to access and undo the knot or twist in the wire. Once this occurs the integrity of the flanges responsible for guiding the wire out of the box are significantly compromised causing more knots to likely occur. When more knots occur the box must be opened again, further weakening the integrity of the box every time it is opened.

Some “snags” in the wire are due to the cardboard flanges inside the box not being flush with the wall of the box. This creates a gap where wire can get stuck until the box is opened, and the wire removed from the gap. Eventually the box becomes unusable and workers will either spend a lot of time trying to fix the box so that the wire can be used or the worker simply throws the remainder of the wire in the trash because it is not viewed as “worth the time” to try to fix the box. Both scenarios cost a company money. Paying the worker for the time it takes to fix a cardboard box that will never truly be usable again or watching money go in the trash because the remainder of the wire is thrown away costs a lot of money over the years.

Many workers keep boxes of wire in the back of a truck or actually out on the job where they are exposed to the elements. Water, snow, sun and cold temperatures all contribute to the weakening of the cardboard resulting in completely ruined and unusable boxes of expensive wire. This leaves the worker to spend exuberant amounts of time trying to figure out how to efficiently use the wire that is no longer able to be dispensed from the box. Thus there is a need for a wire box assembly that overcomes these deficiencies and difficulties.

SUMMARY OF THE DISCLOSURE

One exemplary embodiment of a wire box assembly in accordance with the present disclosure includes a container having a base, four upright side walls and a separable lid. The base has a generally rectangular peripheral shape and has a central inwardly raised portion, preferably circular in shape, with a cruciform projection extending inwardly upward between the upright side walls from the central raised portion.

The lid has a generally rectangular peripheral shape configured to mate with the four upright side walls of the container. The lid has a central inwardly raised portion with a cruciform projection extending inwardly from the central raised portion. This lid cruciform projection is configured to face the container cruciform projection when the lid is attached to the container. Each of the cruciform projections is formed of a plurality of trapezoidal blades.

The cruciform projections may be separately fixed to the raised portions or are most preferably integrally molded into each of the container and the lid. Each of the blades has an angled outer edge extending from the base upward at an angle between 45 and 60 degrees. The blade inner vertical edges join together at the center of the raised portion. One of the side walls of the container has a centrally located opening therethrough opposite the upper edges of each of the cruciform projections when the lid is mated to the container.

An embodiment of a wire box assembly may include a container having a base and four upright side walls. The base has a generally rectangular peripheral shape and has a central raised portion with a cruciform projection extending inwardly upward between the upright side walls from the central raised portion. The assembly includes a separable lid having a generally rectangular peripheral shape configured to mate with the four upright side walls of the container. The lid has a central inwardly directed raised portion with a cruciform projection extending inward from the central raised portion. The lid cruciform projection is configured to face the container cruciform projection when the lid is attached to the container such that the cruciform projections face each other and are spaced apart by a gap. At least one of the side walls has a central opening therethrough facing the gap between the projections.

The cruciform projections are each formed of a plurality of trapezoidal blades. The blades of the cruciform projections are preferably integrally molded into each of the container and the lid. Each of the blades has an angled edge extending from the base upward at an angle between 45 and 60 degrees. At least one of the side walls has an elongated opening extending parallel to an upper edge of the side wall for grasping the container. The lid has a peripheral edge with a plurality of projections extending therefrom to mate with corresponding features in the upright side walls of the container. At least one of the plurality of projections has a hook shape to engage with a corresponding opening in the side wall of the container.

An exemplary embodiment of a wire box assembly in accordance with the present disclosure may be viewed as a wire box assembly for storing and dispensing a coil of wire therefrom. The assembly preferably includes a generally cubical container having a generally square base and four upright side walls. The base has a generally square peripheral shape with rounded edges and has a central raised portion with a cruciform projection extending inwardly upward between the upright side walls from the central raised portion.

The assembly includes a separable lid having a generally square peripheral shape with rounded edges configured to mate with the four upright side walls of the container. The lid also has a central inwardly directed raised portion with a cruciform projection extending inward from the central raised portion. The lid cruciform projection is configured to face the container cruciform projection when the lid is attached to the container. The cruciform projections face each other and are spaced apart by a gap. At least one of the side walls has a central opening therethrough facing the gap between the projections. The container base and side walls preferably merge together along curved outer edges to eliminate sharp corners. The cruciform projections are each preferably formed of a plurality of trapezoidal blades. The cruciform projections may be separate blade structures fastened to the base or may be integrally molded into each of the container and the lid. Each of the blades has an angled edge extending from its base upward at an angle between 45 and 60 degrees. At least one of the side walls has an elongated opening extending parallel to an upper edge of the side wall for grasping the container. The lid preferably has a peripheral edge with a plurality of projections extending therefrom to mate with corresponding features in the upright side walls of the container. Preferably at least one of the plurality of projections has a hook shape to engage with a corresponding opening in the side wall of the container.

These and other features and advantages of embodiments of the present disclosure will become apparent from a reading of the following Detailed Description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded upper perspective view of a wire box assembly container with a lid in accordance with the present disclosure.

FIG. 2 is a lower exploded perspective view of the container and lid of FIG. 1.

FIG. 3 is a side exploded perspective view of the container and lid of FIG. 1.

FIG. 4 is a vertical cross-sectional view of the assembled wire box assembly shown in FIG. 1.

DETAILED DESCRIPTION

Exploded perspective views of an exemplary embodiment of a wire box assembly 100 in accordance with the present disclosure are shown in FIGS. 1-3. The box assembly 100 includes a hollow container 110 and a lid 150. The container 110 is generally rectangular in shape and preferably a cubic box with rounded side edges. The container 110 has a generally rectangular base 112 merging into four upright side walls 114. The base 112 has a central raised portion 116 that is preferably disc shaped. The central raised portion 116 supports a cruciform projection 120 that extends inwardly upward between the upright side walls 114 from the central raised portion 116. The cruciform projection 120 is formed by four trapezoidal blades 122 that are joined together at the center and either integrally molded into the raised portion 116 or separately formed and glued or otherwise fastened thereto. These blades 122 extend upward parallel to opposing side walls 114. Each trapezoidal blade 122 has one edge extending from the base raised portion 116 at an angle of between about 45 and 60 degrees and terminates at a top edge 124 parallel to the base 112.

One of the side walls 114 preferably has an opening 118 therethrough for the passage of wire. This opening 118 is centrally located on that side wall 114 so that it is opposite to and just above the top edge 124 of the blades forming the cruciform projection 120. One of the side walls 114, preferably the same side wall having the opening 118, may have an elongated second opening 126 extending parallel to an upper edge of the side wall 114 for carrying of the box assembly 100. The second opening 126 preferably has a thickened raised rim to minimize sharp corners and will not tear open facilitating ease of carrying the box assembly 100. One of the side walls 114 may also have a third opening 128 therethrough configured to secure one end of the wire coil to be stored within the box assembly 100.

As noted above, the box assembly 100 includes a lid 150. The lid 150 preferably has an inwardly directed preferably circular raised portion 152. The Lid 150 further has a cruciform projection 154 extending at a right angle from the raised portion 152 in a manner identical to that of the cruciform projection 120 described above. The cruciform projection 154 may be integrally molded with the lid 150 or may be separately formed and glued or otherwise fastened to the lid 150 in a conventional manner. The cruciform projection 154 is formed by four trapezoidal blades, each of which is joined to the other at the center and each having an edge that extends from the raised portion 152 at an angle of between about 45-60 degrees.

The cruciform projection 154 is preferably configured to face and mirror the container cruciform projection 120 when the lid 150 is attached to the container 110. The lid 150 may have a generally rectangular peripheral shape. The peripheral portion of the lid 150 is configured to mate with the upper edges of the four upright side walls 114 of the container 110.

With reference now to the sectional view of FIG. 4, the cruciform projections 120/154 together form an hourglass-like structure that has a gap 160 between the cruciform projections 120/154 when the lid 150 is secured to the container 110. This hourglass-like structure facilitates dispensing of the wire and/or prevent knots and snags from forming in the wire as the wire is withdrawn through the hole 118 through the side wall 114.

The opening 118 is preferably circular and is preferably centered on one of the side walls 114 opposite the gap 160. The box assembly 100 may have hinges and snapping locks fastened to the mating container and lid edges for opening and closing the box assembly 100. More preferably, the lid 150 has a plurality of projections 162 extending from one or more of the edges of the lid for engaging corresponding features in the side walls 114 of the container 110. For example, these projections may be hook shaped blades 162 that extend from a peripheral edge of the lid 150 that hook into corresponding openings 164 in the upright walls 114. Alternatively actual hinges may be employed, fastened to the lid and to the side walls 114.

The box assembly 100 is preferably made of a molded polymer such as a thermoplastic material. Alternatively the box assembly 100 may be formed from a corrugated plastic structure. The side walls 114 of the container 110 may be ribbed to increase the rigidity of the side wall structure. The container 110 has a solid, seamless construction so that wire will not get stuck in gap 160 as it is being withdrawn from the assembly 100. The cruciform projections 120/154 are preferably rigid such that they will not bend and/or break during box assembly use. The box assembly 100 is recyclable, and may be sized to contain and/or store various types of wire.

Many variations will be apparent to those skilled in the art. The box assembly may be cubic in shape or have a different shape than as specifically described. For example, the box assembly may have a circular base and a single cylindrical side wall rather than four separate side walls. Thus all such variations and equivalents are within the scope of the present invention as defined by the following claims. 

What is claimed is:
 1. A wire box assembly comprising: a container having a base, four upright side walls and a separable lid; the base having a generally rectangular peripheral shape and having a central raised portion with a cruciform projection extending inwardly upward between the upright side walls from the central raised portion; the lid having a generally rectangular peripheral shape configured to mate with the four upright side walls of the container and having a central raised portion with a cruciform projection extending from the central raised portion, wherein the lid cruciform projection is configured to face the container cruciform projection when the lid is attached to the container.
 2. The wire box assembly according to claim 1 wherein the cruciform projection is formed of a plurality of trapezoidal blades.
 3. The wire box assembly according to claim 2 wherein the cruciform projections are integrally molded into each of the container and the lid.
 4. The wire box assembly according to claim 2 wherein each of the blades has an angled edge extending from the base upward at an angle between 45 and 60 degrees.
 5. The wire box assembly according to claim 2 wherein one of the side walls of the container has a centrally located opening therethrough.
 6. The wire box assembly according to claim 5 wherein the centrally located opening is opposite an upper edge of each of the cruciform projections when the lid is mated to the container.
 7. A wire box assembly for storing and dispensing a coil of wire therefrom, the assembly comprising: a container having a base and four upright side walls, the base having a generally rectangular peripheral shape and having a central raised portion with a cruciform projection extending inwardly upward between the upright side walls from the central raised portion; and a separable lid having a generally rectangular peripheral shape configured to mate with the four upright side walls of the container, the lid having a central inwardly directed raised portion with a cruciform projection extending inward from the central raised portion, wherein the lid cruciform projection is configured to face the container cruciform projection when the lid is attached to the container, wherein the cruciform projections face each other and are spaced apart by a gap, and at least one of the side walls has a central opening therethrough facing the gap between the projections.
 8. The wire box assembly according to claim 7 wherein the cruciform projections are each formed of a plurality of trapezoidal blades.
 9. The wire box assembly according to claim 8 wherein the cruciform projections are integrally molded into each of the container and the lid.
 10. The wire box assembly according to claim 8 wherein each of the blades has an angled edge extending from the base upward at an angle between 45 and 60 degrees.
 11. The wire box assembly according to claim 8 wherein at least one of the side walls has al elongated opening extending parallel to an upper edge of the side wall for grasping the container.
 12. The wire box assembly according to claim 8 wherein the lid has a peripheral edge with a plurality of projections extending therefrom to mate with corresponding features in the upright side walls of the container.
 13. The wire box assembly according to claim 12 wherein at least one of the plurality of projections has a hook shape to engage with a corresponding opening in the side wall of the container.
 14. A wire box assembly for storing and dispensing a coil of wire therefrom, the assembly comprising: a container having a generally square base and four upright side walls, the base having a generally rectangular peripheral shape and having a central raised portion with a cruciform projection extending inwardly upward between the upright side walls from the central raised portion; and a separable lid having a generally rectangular peripheral shape configured to mate with the four upright side walls of the container, the lid having a central inwardly directed raised portion with a cruciform projection extending inward from the central raised portion, wherein the lid cruciform projection is configured to face the container cruciform projection when the lid is attached to the container, wherein the cruciform projections face each other and are spaced apart by a gap, and at least one of the side walls has a central opening therethrough facing the gap between the projections, wherein the container base and side walls merge together along curved outer edges to eliminate sharp corners.
 15. The wire box assembly according to claim 14 wherein the cruciform projections are each formed of a plurality of trapezoidal blades.
 16. The wire box assembly according to claim 15 wherein the cruciform projections are integrally molded into each of the container and the lid.
 17. The wire box assembly according to claim 15 wherein each of the blades has an angled edge extending from the base upward at an angle between 45 and 60 degrees.
 18. The wire box assembly according to claim 15 wherein at least one of the side walls has al elongated opening extending parallel to an upper edge of the side wall for grasping the container.
 19. The wire box assembly according to claim 15 wherein the lid has a peripheral edge with a plurality of projections extending therefrom to mate with corresponding features in the upright side walls of the container.
 20. The wire box assembly according to claim 19 wherein at least one of the plurality of projections has a hook shape to engage with a corresponding opening in the side wall of the container. 